Casting apparatus



Aug. 5, 1969 l.. `w. JEFFREYS CASTING APPARATUS med April 13, 196eUnited States Patent O 3,459,256 CASTING APPARATUS Lyman W. Jeffreys,Mount Prospect, Ill., assignor to Amsted Industries Incorporated,Chicago, Ill., a corporation of New Jersey Filed Apr. 13, 1966, Ser. No.542,335 Int. Cl. B28b 7/02; B22d 17/26; B411) 11/68 U.S. Cl. 164-342 8Claims ABSTRACT F THE DISCLOSURE An adjustable slab mold has a pluralityof inner blocks interposed between opposed main side blocks to define alongitudinal casting cavity. An end block of the mold is biased awayfrom an adjacent bottom block during loose engagement of the innerblocks and is movable on rollers across the cavity defining surface ofthe bottom block. Upon tight engagement of the inner blocks the endblock is forced into contact with the bottom block.

This invention relates generally to the casting of metal articles andmore particularly to a mold apparatus for the pressure casting of moltenmetal.

It is the present practice in the steel industry to cast ingots whichare subsequently processed through various preliminary conditioningoperations such as cropping, grinding and/0r scarfing in order toprepare such ingots for subsequent rolling operations which form theingots into slabs, blooms or billets. These rolled products are thenused to form finished mill products such as beams, plates, sheets orrails.

It has been proposed to cast slabs, billets or blooms in a chill mold bypressure casting. To overcome the necessity for multiple molds toproduce the various sizes of slabs, blooms and billets, an adjustablemold was proposed. The mold is made up of a pair of opposed main blockswhich are moved toward and away from each other for closing and openingthe mold. Adjustable inner blocks are interposed between the main moldblocks for forming cavities of different sizes and proportions byrelatively adjusting the inner blocks.

The inner blocks comprise a top block, a rear end block and bottomblock. These inner blocks with the main side blocks define a cavitytherebetween which is open at the front end. An ingate assembly closesthe front end to complete the definition of the cavity.

Experience indicates that such a mold has been highly successful. Onedrawback does exist in the use of such a mold. The rear end or backblock is arranged to rest on the top surface of the bottom block and ismovable thereon. Since these molds are used to produce very large slabs,etc., the back block must of necessity be relatively large. Thecontinued movement of the back block along the top of the bottom blocktends to wear away this top surface. Since the mold parts are usuallyconstructed of graphite, this wearing away may take place ratherrapidly.

As the surface wears away it changes the linear configuration of themold with the result that non-rectangular slabs may be produced whichmay require some finishing before they are suitable for forming intobeams, plates, etc. In addition, the bottom surface of the back blockmay wear away with the result that the cavity adjustments based on theheight of the back block will not be accurate.

It is therefore an object of this invention to provide an improved moldapparatus for casting metal articles.

Another object of this invention is to provide an ad- 3,459,256 PatentedAug. 5, 1969 ICC justable mold apparatus wherein wear of the moldsurfaces is reduced.

A further object of this invention is the provision of a mold apparatushaving an adjustable cavity wherein the tendency of the mold parts towear is substantially reduced.

These and other objects and advantages of this invention will becomeapparent from a reading of the following detailed description of thisinvention when taken in conjunction with the accompanying drawingwherein:

FIGURE l is a partial cross sectional View in elevation of the moldapparatus of this invention, and

FIGURE 2 is a cross sectional view of the mold lifting apparatus of thisinvention.

The mold apparatus of this invention is especially suitable for thepressure pouring of slabs, billets and blooms.

Referring now to the drawings, reference number 10 denotes an adjustableslab mold mounted on a carriage 12. The mold 10 is made up of two mainside blocks 14, only one of which is shown in the drawing, and aplurality of inner blocks. The two side blocks 14 are identical inconfiguration.

The inner blocks are a top block 16, a bottom block 18 and a rear endblock 20. The two main side blocks are fitted together and engage innerblocs 16, 18 and 20 therebetween, defining a mold cavity 22 which isopen at its front end. The open end of the cavity 22 is closed by aconventional ingate assembly 24. The blocks of the mold 10 arepreferably constructed of graphite.

The top and bottom blocks 116 and 18 are preferably substantially thesame length as the main side blocks 14. The bottom block 18 extendsbelow the main side blocks 14 throughout most of its length, but it hasa reduced end portion 2'5 which may be approximately ush with the lowersurface of the main side blocks 14. The bottom block 18 normally remainsfixed on the carriage 12. It is mounted on a rail 26 supported ontransverse beams 28' of carriage 12.

The top block '16 is supported by a plurality of hangers or supports 30which are adjustable in order that the position of top block 16 withrespect to the main side blocks 14 may be adjustable for different sizesof slabs, etc. Reference may be had to the above-identified applicationfor further details of the mounting and adjustment of the side blocks 14and the inner blocks 16 and 1S.

The top, bottom and rear end blocks are selected as to size from thestandpoint of the thickness of the slab to be cast. For example,customary slabs may be 5, 6 or 7 inches in thickness and for each ofthese thicknesses, a corresponding set of blocks is utilized in themold.

The rear end block 20 is preferably formed of graphite and it isprovided on its upper surface 32 with a vent block 34. The vent block 34is provided with apertures 36 which permit gas to escape therethoughduring the pouring of molten metal into the assembled mold 10. The rearblock 20 is provided with a backing plate 38 secured by conventionalmeans, such as screws (not shown), to the block. The plate 3-8 providesmeans for attaching the adjusting mechanism 40 to the rear end block 20.

The adjusting mechanism 40 is provided with power means which comprisesa pair of hydraulic or air cylinders 44. These cylinders 44 are mountedon brackets 46 which are mounted on support `48 incorporated in thestructure of the mold carriage 12. Secured to each cylinder 44 is apiston rod 50 which extends from cylinders 44 through bushings 52 insupport 48 to threaded sockets 54 of the lifting mechanism 56 for rearend block 20. Rearward movement of the lifting mechanism 56 which issupported on bracket 58 secured to support 48 is limited by stops 60,also secured to support 48.

The lifting mechanism 56 comprises a plate member 62 to which thethreaded sockets 54 are welded or otherwise secured. The sockets 54 areon the side of the plate member 62 opposite that of the rear end block20. yOn the other side of plate member 62, a bracket 64 is formed orsecured. The bracket 64 is formed of two side plates 66 which extendoutwardly from the surface of the plate member 62 in the direction ofthe rear end block 20. On the lower ends of the side plates, an ear 68is formed, the purpose of which will be explained hereinbelow. The twoside plates 66 are joined by joining members 70, each of which isprovided with a vertical bore 72 in vertical alignment with each other.The three joining members 70 are spaced from each other to provide openareas between the two side plates 66. In the illustrated embodiment, onemember 70 is near the top of the side plates 66, another near the bottomand the third, intermediate the other two, thereby providing a space 74in the upper half of the lifting mechanism 56 and a space 76 in thelower half of the same.

The vertical bores 72 of joining members 70 are provided with sleevebushings 78 which are utilized to retard movement of rod 80 which isretained in place by screw 81. The rod '80 extends from above theuppermost joining member 70 down through the middle member 70 and intothe lowermost member 70. Rod 80 is utilized to retain connecting member82 in vertically movable relationship to the lifting mechanism 56.Connecting member 82 may be of any suitable configuration. In theillustrated embodiment, it includes a flat side 84 joined to backingplate 38 of rear end block 20 by any suitable means as by welding or byscrews (not shown). A side plate 86 is secured to the flat side `84which at its end remote from side 84 is provided with two ears `88. Theears 88 are provided with vertical bores 90 which receive therein sleevebushings 92. The bushings 92 are constructed and arranged to receive insliding relationship rod 80 in order that connector `82 is movablevertically with respect to lifting mechanism 56.

The ears 88 are constructed and arranged to be received in open spaces74 and 76 of `bracket `64. The ears 88 are supported for verticalmovement on springs 94. The springs 94 are placed around rod l80. Thelowermost spring 94 rests on lowermost joining member 70 and the secondspring 94 rests on the middle joining member 70, thereby urging ears y88and connector 82 upwardly. The springs 94 are sufliciently strong tosupport rear end block and its associated mechanism.

As indicated above, an ear 68 is formed on the lower end of each of theside plates 66. An axle 96 extends between the two ears 68 and the -axle96 has a roller 98 mounted thereon in rotary relationship. The roller 98is adapted to roll along the upper surface 100 of the bracket 58 and theupper surface 104 of the bottom block 18 which is in alignment with thetop surface 100 of the bracket 58. -If desired, a sliding plate may besubstituted for roller 98, which roller, however, is the preferredembodiment.

In operation, the bottom block 18 is placed in position. The rear endblock is then moved to the desired position by activating the twocylinders 44. Pressure applied to the cylinders moves piston rods 50 totheir right, thereby moving lifting mechanism 56 to its right. Sincethere is no weight added to the rear block 20` at this point, it islifted out of contact with the top of the bottom block 18 by the springs94 pushing up on the ears 88. This lifts connecting member and the rearend block. The roller 98 remains in contact with the bracket 58 androlls along its top surface 100 to the desired position for rear endblock 18 on the top surface 104 of the bottom block. The top block 16 isthen lowered by supports 30 until it contacts the vent block 34 andforces the same along with rear block 20 downwardly until rear block 20contacts the bottom block 18. The main side blocks 14 are then closed toform the cavity 22 which is then closed by ingate assembly 24. Theassembled mold 10 is now rolled into place over the pouring tube 102 ofa conventional pressure pouring tank where air tight connection is madebetween the ingate assembly 24 and the pouring tube 102 for the pressurepouring of the slab.

Following casting of the slab, the mold 10 is opened by reversing thesteps for assembling the mold. As soon as the top block 1'6 is liftedout of contact with the vent block 34, the springs 94 lift the connector82, thereby lifting rear end block 20 out of contact with the bottomblock 18. The rear end block 20 may then be moved out of the mold orotherwise moved to adjust the size of the cavity 22.

It can be seen from the foregoing that by lifting the rear end block 20out of contact with the bottom block 18 during adjustment of the cavityof the mold, the tendency of the top surface of the bottom block to wearis substantially, if not completely, eliminated. Wear of the bottom ofthe rear end block is also substantially eliminated.

While one embodiment of this invention has been described hereinbefore,it should be understood that various modilications may be made in thisapparatus without departing from the spirit and scope of the annexedclaims. For example, the power means may comprise a motor having arotary connection with screws substituted for the two piston rods 50thereby rotating the screws in order that the back block may be suitablypositioned. The roller 98 may be replaced by a spring biased slide.

I claim:

1. An adjustable mold apparatus having a plurality of mold blocks, atleast one of said blocks being movable relative to the molding positionof said other blocks, said movable block in its molding position restingon the top of one of said other blocks, means for lifting said movableblock out of contact with said other block during movement of saidmovable block relative to Said -other block, and roller means supportingsaid lifting means for rolling engagement with said other block duringsaid relative movement.

2. An adjustable mold apparatus according to claim 1 wherein saidlifting means is secured to said movable block.

3. In an adjustable mold having a plurality of mold blocks defining acasting cavity and at least one block movable in a horizontal directionrelative to said other blocks to vary the size of the cavity, saidmovable block in its cavity-defining position being in contact with anupper surface of one of said other blocks, means for lifting saidmovable block vertically out of contact with said surface of the otherblock and maintaining it in said lifted position during movement to saidmovable block relative to said other block, whereby to reduce wear ofsaid movable and other blocks.

4. The invention set out in claim 3 wherein said lifting means issecured to said movable block and said movable block is resilientlysupported.

5. The invention set out in claim 4 including means for supporting saidlifting means for gliding movement across the surface of said otherblock.

6. The invention set out in claim 3 wherein said lifting means issecured to said movable block and includes means for moving said movable`block relative to said other block.

7. The invention set out in claim 3 wherein said adjustable moldcomprises side block and adjustable inner blocks interposed between theside blocks to define a longitudinal casting cavity, said movable blockis an inner end block usable t-o vary the cavity size longitudinally,said other block is an inner bottom block; and said lifting means issecured to said inner end block.

8. The invention set out in claim 7 including roller means secured tosaid lifting means for supporting said lifting means for rollingengagement with said inner bottom block, and spring means engaged withsaid lifting 3,459,256 .5 6 means for resiliently supporting said innerend block rela- FOREIGN PATENTS tive to said roller means. 899,2925/1945 France.

J. SPENCER OVERHOLSER, Primary Examiner 5 R. SPENCER ANNEAR, AssistantExaminer References Cited UNITED STATES PATENTS 2,289,928 7/ 1942yParker 164-342 3,263,277 8/ 1966 -Ohlendorf etal. 164--343 X U.S. C1.X.R. 3,340,926 9/ 1967 Sylvester 249--158 X 249-158 3,340,798 9/1967Winger 249-158 X

